DE102016123491A1 - Casting device, press and method for casting a component and component - Google Patents

Abstract

The invention relates to a casting device for casting a component by means of a tool, which has a mold for forming the component, wherein the casting device has a tool holder for receiving the tool, with at least two Dosierkavitäten, which in each case a fluid connection is assigned, so located in the Dosierkavitäten Melting in the form are transferable. Furthermore, the invention relates to a press and a method for casting a component.

Description

The invention relates to a casting device for casting a component by means of a tool, which has a mold for molding the component and the casting device has a tool holder for receiving the tool. Furthermore, the invention relates to a press and a method for casting a component and a component.

In customary die casting processes, the casting mold is filled with melt from a central casting unit by a movement of a driven casting piston. In this case, the casting unit is usually arranged outside of the casting tool, so that there is a long flow path of the melt up to the mold to be filled.

The disadvantage is that due to the temperature loss of the melt along the flow path, the casting time is limited because the melt already begins to solidify on the flow path. This requires a high flow rate of the melt, which in turn leads to abrasive wear of the tool and / or the mold. In addition, the fluidic resistance on the flow path leads to a high required drive energy and / or a high required casting pressure in the mold.

The above-mentioned disadvantages also exist if the melt is not supplied centrally at one point of the mold but is divided into partial streams via a sprue system with branches and enters the mold at several points.

Consequently, the known pouring devices and casting methods for the above-mentioned reasons with respect to the manufactured wall thickness, strength and the production of large-scale parts are limited.

The object of the invention is to improve the state of the art.

The object is achieved by a casting device for casting a component by means of a tool which has a mold for forming the component, wherein the casting device has a tool holder for receiving the tool, with at least two Dosierkavitäten, which in each case a fluid connection is assigned, so in the Dosing cavities located melts are transferable into the mold.

This eliminates or eliminates a central casting unit and / or a sprue system with branches.

Because each dosing cavity is connected directly to the mold via a fluid connection, there is a shorter flow path to the mold. Consequently, the casting process can be performed significantly slower and / or with lower casting pressure than when using a central casting unit. Consequently, the mold and / or tool wear is reduced.

Since no complex branched sprue system is used, but in each case a fluid connection which directly connects a dosing cavity as a local melt reservoir with the mold to be filled, the proportion of the solidified melt which remains in the fluid connection after the casting process has been reduced is reduced in weight. Consequently, the waste to be disposed of and / or the circulation material are reduced.

With regard to the projected tool surface, the locally arranged metering cavity with the short fluid connection leads to a smaller closing surface of the tool and thus to a lower required closing force of the casting device and / or press.

Furthermore, the casting tool can be designed and manufactured more simply due to the omission of the sprue node and the omitted branched sprue system. In particular, the metering cavities in the tool can be manufactured together with the construction of the mold.

An essential idea of the invention is based on the fact that a plurality of local metering cavities are arranged close to and / or within the mold cavity, so that the mold cavity is filled by these multiple local metering cavities via in each case a very short fluid connection.

The following conceptual is explained

A "casting device" is in particular a device for casting a component. A casting device has, in particular, at least two metering cavities as metering containers, at least two fluid connections and a shaping tool. The casting device can be assigned a central melt container with liquid melt.

"Casting" is in particular a manufacturing process in which a solid material of a certain shape is formed from a liquid material (melt) after solidification. For casting, in particular, a tool is used as a permanent mold. Casting includes in particular die casting, die casting and / or continuous casting.

A "component" is in particular an item made of a workpiece of a technical complex, such as a machine or an apparatus. The component is created in particular plastic due to a change in shape through targeted casting and / or forming. Thus, a component in particular almost finished or finished shapes or geometries.

A "tool" is in particular an object in which a machining of a workpiece and / or a casting for the manufacture of a component takes place, wherein the tool is guided by a human and / or a machine. A tool is in particular a molding tool. The tool is used in particular in a forming manufacturing process, such as preforming, forming and / or master molding such as casting. The tool is used in particular in a casting apparatus and / or a press. The tool may consist of a single tool part which directly has the shape of at least two tool parts, for example a lower and an upper tool, or a plurality of tool parts which form the mold in the case of closing the tool. Furthermore, the tool can also have other, not the form-forming tool parts. The tool may have an inner contour, which is applied as an outer contour of the component to be cast.

A "mold" is understood in particular to mean a cavity of the tool whose inner contour is impressed on the workpiece as an outer contour and / or in which the cavity of the mold is filled with melt to produce the component. A mold is also referred to in particular as a "mold cavity".

A "tool holder" is a component that receives and / or holds the tool during casting and / or machining. The tool holder in particular allows a quick change of the tool and / or provides an interface between the tool and drive.

A "dosing cavity" is, in particular, a dosing container for melt which is arranged locally close to, and / or in the mold. In particular, the metering cavity absorbs only a portion of the melt, which is necessary for filling the mold. In particular, the various partial melts of the individual locally arranged metering cavities together produce at least the volume of melt which is necessary for complete filling of the mold. The metering cavity may be a recess closed on three sides in the tool and / or in the mold for receiving the melt. Likewise, the metering cavity may be an open-topped container which is inserted into the tool and / or the mold.

A "fluid connection" is, for example, a cavity which allows a connection between a metering cavity and the mold so that the melt can flow out of the metering cavity into the mold. The fluid connection may be a pipe or a channel. However, a fluid connection may also be a direct opening between the metering cavity and the mold, so that in this case the fluid connection has only a very short elongated extent of a few millimeters. The melt flows through the fluid connection, in particular due to gravity and / or by an applied casting pressure.

A "melt" is, in particular, molten metal and / or metal alloys.

In a further embodiment, the casting device comprises the first metering cavity, the first fluid connection, the second metering cavity and the second fluid connection and / or a third metering cavity and a third fluid connection, a fourth metering cavity and a fourth fluid connection, a fifth metering cavity and a fifth fluid connection and / or another dosing cavity and another fluid connection.

Thus, a plurality of metering cavities, each with a fluid connection can be arranged locally according to the shape of the component to be cast and / or further demands on the component. Here, the position, number and / or size of the metering cavities depends on the mass distribution of the component to be manufactured. Above all, the production of large-area components and / or a minimization of the wall thickness and / or an increase in the strength of the component is or will be made possible.

The third, fourth, fifth and / or further dosing cavity corresponds in terms of design and function to the dosing cavity defined above.

A third, fourth, fifth and / or further fluid connection corresponds in its design and function to the above-defined fluid connection.

In order to cast complex and / or large-area components, the tool has a first tool part and a second tool part, which form the shape in the case of closing.

Of course, the tool may also have a third, fourth, fifth and / or further tool part, in particular if special geometries and / or very large-area components to be cast.

In a further embodiment, the first tool part and the second tool part aligned horizontally or vertically by means of the tool holder.

Compared to the usual vertical orientation of the tool parts and mold in conventional casting, thus a horizontal arrangement of the tool parts and the shape is possible.

In order to transfer the melt from each metering cavity through the respective fluid connection into the respective mold with a corresponding pouring pressure and / or flow rate, the pouring device has a first punch, a second punch, a third punch, a fourth punch, a fifth punch and / or another stamp on, so that the melt is displaced in the respective Dosierkavität by dipping the respective punch on the respective fluid connection in the mold.

In a horizontal alignment of the tool parts, a stamp preferably dives from above into the Dosierkavität. In the case of a vertical alignment of the tool parts, the stamp is moved laterally into the dosing cavity and must therefore seal the dosing cavity with the melt before the dosing cavity is filled. In this case, the filling of the dosing cavity takes place, for example, by means of an additional filling opening arranged at the top in the dosing cavity.

A "stamp" (also called "metering bolt") is in particular a component which, due to its movement, displaces the melt in a metering cavity and thereby presses it into the mold through the associated fluid connection. For example, a punch may be a cylinder of solid material with or without venting. The shape of the punch is particularly matched to the inner shape of the metering cavity, so that the punch can dive flush into the associated Dosierkavität.

In a further embodiment of the casting apparatus, the metering cavity is arranged on and / or in the first tool part and the punches on and / or in the second tool part or vice versa.

Thus, the plunger for immersion in the respective Dosierkavität not each need their own drive, but the immersion of the punch can be realized by a movement of the first tool part and / or the second tool part. For this purpose, the length of each stamp is matched to the corresponding end position of the movable first tool part and / or the second tool part. The punches and / or the dosing cavities can be arranged flush, protruding and / or recessed on the first tool part and / or on the second tool part.

In order to keep the amount of solidified melt after casting and thus the accumulation of waste and / or circulation material and the explosive surface small, the metering cavities are arranged directly on and / or in the mold so that the fluid connection or the fluid connections have a length less than 50mm , in particular less than 20mm, preferably less than 5mm or have.

Thus, a Dosierkavität also be part of the mold.

It is particularly advantageous if the fluid connection is designed only as a direct opening between the metering cavity and the mold.

In addition, the air volume in the fluid connection, which is present before casting, is reduced by a very short fluid connection, so that less air is introduced into the mold during casting. This will cast a more homogeneous component.

In a further embodiment, the casting device has at least one casting robot and / or a melt container.

As a result, the metering cavities can be filled with melt by means of at least one casting robot from a melt container. Preferably, each dosing cavity is filled by its own casting robot, so that all dosing cavities can be filled at the same time.

A "pouring robot" is in particular a robot with a mounted ladle for the automated drawing of melt from the melt container into a metering cavity. When scooping through the casting robot in particular the required amount of melt for each filling of the dosing cavity is accurately measured by positionally accurate inclination of the ladle over a distance measurement.

A "melt container" is a container into which a solid is melted into a liquid melt. From the melt container, in particular the melt for each dosing cavity to be filled is removed by means of a casting robot or several casting robots.

In a further aspect of the invention, the object is achieved by a press for casting a component, wherein the press has a drive for applying a pressing force, with a casting device described above.

Thus, not only a pressing force can be applied via the drive of the press, but also previously by a movement of a tool part by dipping the stamp into the metering cavities filled the mold. Thus, there is or are no separate drive and / or separate hydraulic cylinder for the punch movement necessary.

Consequently, the press can be made in a smaller size. In addition, with the press according to the invention also large-area components, in particular in a horizontal orientation, are manufactured, so that the overall height of the press is reduced compared to a vertical orientation.

A "press" is in particular a forming machine with rectilinear relative movement of the tool. In particular, manufacturing processes such as prototyping, casting, forming, deep-drawing, joining, coating, separating, cutting and / or changing material properties are carried out in a press. In particular, a press is a bound, energy or force press.

In a further embodiment of the press, the first tool part and / or the second tool part has or have a movable tool part and a fixed tool part, so that a movement of the stamp can be realized free of application of the pressing force via the movable tool part.

By dividing the first and / or the second tool part into a movable tool part and a fixed tool part can first on the movable tool part, the punch movement for filling the mold and then a movement of the fixed tool part compacting and repressing the melt and pressing the cast Component due to the application of the pressing force to the fixed tool part and the movable tool part done. Thus, both the filling of the mold and the actual pressing can be realized by means of a single tool with a movable and a fixed part.

• - Befüllen von wenigstens zwei Dosierkavitäten mittels wenigstens eines Gießroboters mit Schmelze,
• - Schließen des ersten Werkzeugteils und des zweiten Werkzeugteils zum Ausbilden der Form,
• - Eintauchen von jeweils einem Stempel in die jeweilige Dosierkavität durch eine Bewegung des ersten Werkzeugteils oder des zweiten Werkzeugteils und Verdrängen der Schmelze aus den Dosierkavitäten durch die Fluidverbindungen in die Form,
• - Verbinden der Schmelzen in der Form zu einem homogenen Bauteil.

In an additional aspect of the invention, the object is achieved by a method for casting a component by means of a previously described casting device and / or a previously described press, comprising the following steps:

• Filling at least two metering cavities by means of at least one casting robot with melt,
• Closing the first tool part and the second tool part to form the mold,
• Immersing one stamp in the respective metering cavity by moving the first tool part or the second tool part and displacing the melt out of the metering cavities through the fluid connections into the mold,
• - Connecting the melts in the mold to form a homogeneous component.

Thus, a simplified method for casting a component is provided in which over locally arranged metering cavities, a filling of the mold and thus a casting of the component takes place. Above all, the method makes it possible to cast a homogeneous and / or large-area component.

In a further aspect of the invention, the object is achieved by a component, wherein the component is manufactured according to a method described above.

Due to the adaptation of the position, number and / or size of the dosing cavities to the mass distribution of the component to be manufactured a very homogeneous component is manufactured with increased strength. In addition, components with smaller wall thicknesses and / or larger components can be manufactured.

• 1 eine schematische Schnittdarstellung einer Presse mit einer Druckgießvorrichtung und einem geöffneten Werkzeug mit Dosierkavitäten und Dosierbolzen,
• 2a die Presse aus 1 mit geöffnetem Werkzeug und gefüllten Dosierkavitäten,
• 2b die Presse aus 2a mit geschlossenem Werkzeug und eingetauchten Dosierbolzen,
• 2c die Presse aus 2b mit weiterem Eintauchen der Dosierbolzen und Nachverdichten, und
• 2d die Presse aus 2c bei Konstanthalten der Presskraft.

Furthermore, the invention will be explained in more detail with reference to embodiments. Show it

• 1 FIG. 2 a schematic sectional view of a press with a die casting device and an opened tool with metering cavities and metering bolts, FIG.
• 2a the press out 1 with opened tool and filled dosing cavities,
• 2 B the press out 2a with closed tool and immersed dosing bolts,
• 2c the press out 2 B with further dipping of the metering bolts and re-compaction, and
• 2d the press out 2c at constant pressure.

A press 101 has a die casting device 103 and a tool 105 on. The tool 105 consists of the upper tool base plate 111 , the shaping upper tool 107 and the lower tool 109 , The upper tool base plate 111 is on a press ram 117 attached and has two dosing 123 on. The upper tool base plate 111 is over two springs 125 with the movable shaping upper tool 107 connected. The upper tool 107 has two spacers above 128 opposite the upper tool base plate 111 on.

The lower tool 109 is at a press table 119 attached and has two Dosierkavitäten 121 on. On both sides of the edge of the lower tool 109 are two distance cylinders 127 appropriate. Below the press table 119 is a table ejector plate 129 arranged.

In case of closing the tool 105 form the upper tool 107 and the lower tool 109 the mold cavity 113 from.

The dosing bolts 123 are in their length to a lower end position of the upper tool 107 Voted. The distance cylinders 127 of the lower tool 109 have an upper and a lower end position.

The following operations are done with the press 101 , the die casting device 103 and the tool 105 realized:

With the tool open 105 is the press ram 117 at top dead center. The movable upper tool 107 has been lowered and is using a spring force of the springs 125 kept in its lower position. By means of two pouring robots, not shown, the two metering cavities 121 of the lower tool 109 filled with a respective required melt volume from a central melt container, not shown. The distance cylinders 127 in the lower tool 109 stand here in their upper end position.

After filling the dosing cavities 121 is due to a movement of the press ram 117 down in a closing direction 131 the tool 105 closed. On the one hand, this is the upper tool 107 furthermore in addition to the weight force by the acting springs 125 with a preselected force pressed down and on the other hand now additionally when closing the tool upwards against the closing direction 131 pressed until the spacers 128 a path between the movable upper tool 107 and the upper tool base plate 111 limit. Only at the stop of the spacer elements 128 to the upper tool base plate 111 is a ram force greater than the spring force on the upper tool 107 transferable.

By placing the upper tool 107 on the distance cylinders 127 of the lower tool 109 becomes the mold cavity 113 closed. In this case, however, the mold cavity 113 is not yet closed to the extent that a wall thickness of a component to be manufactured is reached. Closing in the closing direction 131 is continued, with the dosing 123 into the dosing cavities 121 immerse and the melts from the dosing cavities 121 in the directly connected mold cavity 113 displace. Here, the closing force between the upper tool 107 and lower tool 109 only from a weight of the movable upper tool 107 and the springs 125 so that no higher casting pressure is produced in the tool 105.

Filling the mold cavity 113 will stop when the spacer element 128 between the fixed upper tool base plate 111 and the movable upper tool 107 sit up and transfer a force. Then the distance cylinders 127 relieved in the lower tool 109 and the upper tool base plate 111 and the movable upper tool 107 will continue in the closing direction 131 moves until the tool 105 as far as it is concluded that the actual wall thickness of the component to be cast is reached. The dosing bolts dip 123 further into the dosing cavities 121 and compact the cast component. In this recompression at the same time the ram force is exerted on the cast component over an entire surface of the tool 105.

The ram force is maintained and after solidification of the cast component becomes the tool 105 open. Subsequently, the component for removal via the Tischauswerferplatte 129 in the press table 119 raised.

Thus, a press with die casting and a tool with integrated Dosierkavitäten and dosing provided, which allow very short flow paths to the mold cavity, a low mold and tool wear and a low scrap material. In addition, a very homogeneous component with a complex, large-area geometry is manufactured.

LIST OF REFERENCE NUMBERS

101

Press

103

die casting

105

Tool

107

upper tool

109

lower tool

111

Upper tool base

113

mold cavity

117

press ram

119

press table

121

metering cavity

123

Dosierbolzen

125

feather

127

Distance cylinder

128

spacer

129

Tischauswerferplatte

131

closing direction

Claims (12)

Casting device (103) for casting a component by means of a tool (105), which has a mold (113) for forming the component, wherein the casting device has a tool holder (111, 119) for receiving the tool, characterized by at least two metering cavities (121 ), which in each case a fluid connection is assigned, so that located in the metering cavities melts are transferable into the mold. Casting device after Claim 1 characterized in that the casting apparatus comprises the first metering cavity, the first fluid connection, the second metering cavity and the second fluid connection and / or a third metering cavity and a third fluid connection, a fourth metering cavity and a fourth fluid connection, a fifth metering cavity and a fifth fluid connection and / or another dosing cavity and another fluid connection. Casting device according to one of the preceding claims, characterized in that the tool has a first tool part (107) and a second tool part (109), which form the mold in the case of closing. Casting device after Claim 3 , characterized in that the first tool part and the second tool part are aligned horizontally or vertically by means of the tool holder. Casting device according to one of the preceding claims, characterized in that the casting device has a first punch (123), a second punch, a third punch, a fourth punch, a fifth punch and / or another punch, so that the melt in the respective Dosierkavität is displaced by dipping the respective punch on the respective fluid connection in the mold. Casting device according to one of Claims 3 to 5 , characterized in that the metering cavities are arranged on and / or in the first tool part and the punches on and / or in the second tool part or vice versa. Casting device according to one of the preceding claims, characterized in that the metering cavities are arranged directly on and / or in the mold, so that the fluid connection or the fluid connections has a length less than 50mm, in particular less than 20mm, preferably less than 5mm or have. Casting device according to one of the preceding claims, characterized in that the casting device has at least one casting robot and / or a melt container. Press for casting a component, wherein the press has a drive for applying a pressing force, characterized by a casting device according to one of Claims 1 to 8th , Press after Claim 9 , characterized in that the first tool part and / or the second tool part a movable tool part (107) and a fixed tool part (111) or have, so that on the movable tool part, a movement of the stamp is free of application of the pressing force can be realized. Method for casting a component by means of a casting device according to one of Claims 1 to 8th and / or a press Claim 9 or 10 Characterized by the following steps: - filling at least two metering cavities using at least one Gießroboters with melt, - closing of the first tool portion and second tool portion for forming the mold, - Exchanging each a punch into the respective metering cavity by a movement of the first tool part or the second tool part and displacement of the melts from the metering cavities via the fluid connections into the mold, - connecting the melts in the mold to form a homogeneous component. Component, characterized in that the component according to a method Claim 11 is made.

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